Custom Chemical Blends: Tailoring Solutions to Industry Needs

Many manufacturers who choose to use commodity chemicals for their process will cite cost as the primary reason: common chemical blends are cheaper than custom solutions.

If you asked our customers, many would say they choose custom chemicals for the same reason: cost!

While the up-front cost of investigating a facility, identifying a solution, and producing a custom solution is indeed more expensive than using a generic solution, the long-term view is quite different. Custom chemicals are a proven and effective way to improve manufacturing efficiency and product quality—two factors that directly impact margins.

Even two facilities running identical equipment will have specific needs that custom chemicals can address. Perhaps one facility’s equipment has more wear and tear as they keep their line running longer. Maybe each facility machines slightly different grades of steel. Factors like ambient temperature and altitude can have subtle effects on manufacturing processes.

Custom chemicals can address and account for each of these minor differences. Benefits may be immediate or long-term: reduced operating costs, increased equipment longevity, or even improved product quality.

How Americo approaches custom chemistry

Americo believes in the power of quality management to enhance processes and improve ROI. As an ISO 9001:2015 certified company, we specialize in quality management and process engineering. By improving product quality, our clients have an opportunity to grow and improve their brand reputation and awareness. They may be able to raise prices and improve margins, competing on quality rather than struggling in a price-based, commodified race to the bottom.

It’s part of what we call a Total Systems Approach to chemistry. Total Systems Approach involves research and analysis to uncover unexpected sources of value. It’s a repeatable process we employ to affect long-term positive change for manufacturers of all kinds.

For example, a Total Systems Approach may involve installing sensors to monitor particular attributes and outcomes during your manufacturing process. Data from the sensors combined with information provided by operators and our own professional analysis will inform which additives and adjustments will make your chemicals more effective. Perhaps overheating during the cutting process wears down tools too quickly. Additives with cooling and hardening properties may improve the longevity of tools and equipment, resulting in lower maintenance costs.

Common additives for manufacturing chemicals

There are many additives used in manufacturing chemistry. Let’s look at some of the most common types of additives and how they can benefit your process.

Metalworking fluids

• Corrosion inhibitors like borates and phosphates prevent rust and corrosion. These can protect your equipment or workpieces, reducing costs and product quality.
• Biocides prevent the growth of harmful bacteria, fungi, and other organisms in fluids. This extends the usable lifespan of fluids while reducing odor and protecting workers from potential health concerns.
• Anti-foaming agents reduce the formation of foam and bubbles. Foaming can reduce the effectiveness and coverage of fluids as well as cause equipment issues and cleanup challenges.
• Cooling agents can prevent overheating issues and increase the longevity of cutting tools.

Metal Coatings

• UV stabilizers and absorbers protect the coating from degradation due to ultraviolet light exposure, extending the life of the coating.
• Anti-corrosive agents like zinc phosphate and chromates are used to protect the metal substrate from corrosion.
• Hardening agents such as crosslinkers react with the polymer matrix to form a harder, more durable coating.
• Plasticizers are added to increase the flexibility of the coating, reducing the risk of cracking or peeling.
• Pigments and dyes provide color and other properties such as corrosion inhibition or light reflection.

Process Water Solutions

• Scale Inhibitors like phosphonates prevent the formation of scale, which can clog pipes and reduce heat exchange efficiency.
• Antimicrobials control microbial growth in the water, which can lead to biofouling and degradation of water quality.
• Flocculants and Coagulants are used to aggregate suspended solids for easier removal from wastewater.
• pH Adjusters maintain the optimal pH level for the process, ensuring the stability of the water solution and preventing corrosion or scaling.

 Your Partner in Custom Chemistry

Our commitment to quality and deep experience in manufacturing processes throughout the United States make us an ideal partner for your chemical supply needs. Our blending facility is ready to take your order! Whether you need general chemical supply, toll blending of an existing custom solution, or quality management and process chemical engineering, we’re available to help.